Method for mounting a surgical blade onto a scalpel and for subsequently removing the blade from the scalpel using a package incorporating a pivotable flap

ABSTRACT

A surgical blade package facilitates the mounting of a surgical blade on to the forwardly-projecting cleat on a scalpel handle; and following use in the O.R., the surgical blade package facilitates stripping the used blade off the scalpel for disposal in a sharps container. The cleat is inserted beneath the rear end portion of the blade, and between the blade and the bottom wall of the blade package; and forward and upward movement of the scalpel snaps the blade on to the scalpel in a continuous movement. The opposite procedure is used to demount the used blade from the scalpel and encase it in the original blade package for disposal in a sharps container.

CROSS REFERENCE TO RELATED APPLICATION

This application is a division of application Ser. No. 10/999,133 filedNov. 29, 2004 now U.S. Pat. No. 7,036,660, the entire disclosure ofwhich is hereby incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to a surgical blade package for safelymounting a surgical blade on a scalpel handle, thereby avoidingaccidental or inadvertent cuts.

BACKGROUND OF THE INVENTION

In our prior inventions, as disclosed and claimed in our U.S. Pat. Nos.

-   -   5,433,321    -   5,528,811    -   5,662,221        —a blade package is disclosed and claimed, comprising a        molded-plastic closed “box”, wherein the blade is retained by a        pivoted flap, and wherein the forwardly-projecting cleat on the        scalpel handle is inserted downwardly and forwardly into the        exposed mounting slot in the blade to removably secure the blade        on the cleat as the flap is pivoted away to completely disengage        the scalpel from the package.

While these earlier patents are fully operational and satisfactory forthe purposes intended, the present invention is the culmination offurther developments and constitutes a substantial improvement thereon.

SUMMARY OF THE INVENTION

The present invention provides a surgical blade package for more easilyand conveniently mounting a surgical blade on the forwardly-projectingcleat of a scalpel, thereby substantially minimizing the risk of injuryby an accidental or inadvertent contact with the blade. The blade has atip and further has a mounting slot formed therein. The surgical bladepackage includes a molded-plastic package having an open top andsidewalls, a bottom wall, a closed end wall and an open end oppositelyof the closed end wall, respectively. A transverse ledge is disposedbetween the side walls, such that the blade is supported on the ledgebetween the side walls; the blade is substantially parallel to thebottom of the package; the tip of the blade is pointed in the directionof the closed end wall of the package; and the blade has a rear portionin juxtaposition to the open end of the package. A hold-down pivotabletab is integrally connected to the closed end wall by a living hinge.This tab partially covers the open top for retaining the blade withinthe package.

An important feature of the present invention is this: The cleat of thescalpel is inserted through the open rear end of the package beneath therear portion of the blade and between the blade and the bottom wall ofthe package; the cleat on the scalpel is inserted into the slot in theblade; and the tab is pivoted upwardly away from the package as theblade is separated completely from the package.

In a preferred embodiment, the side walls are substantially parallel andhave concavely-formed indented (“scalloped”) portions adjacent to theopen end of the package, such that the package may be convenientlygrasped between the thumb and forefinger of one of the hands of thenurse or technician while his or her other hand is holding the scalpel,thereby providing additional leverage in separating the package from theblade on the scalpel.

In another embodiment, the package has an upstanding stud on the bottomwall thereof; and the blade has a hole formed therein to receive thestud, thereby positioning the blade laterally of the side walls of thepackage.

Preferably, one of the side walls of the package terminates short of theopen end of the package, thereby conforming to a slanted raised portionof the conventional scalpel handle rearwardly of the cleat thereon.

Another important feature of the present invention is this: The blademay be subsequently removed from the scalpel following use of the bladeduring a surgical procedure in an operating room or other medicalenvironment by reinserting the scalpel with the blade thereon into theoriginal package, thereby stripping the blade from the cleat on thescalpel; and the tab is pressed down on the blade to retain the blade,such that the package with the used blade therein may be placed into asharps container.

Preferably, cooperating nibs are formed between the pivotable tab andthe package, thereby releasably holding the tab down on the blade, suchthat the cooperating nibs are released as the cleat on the scalpel ismounted into the slot in the blade and the scalpel is moved away fromthe package.

A sealed, sterile, pouch may be provided for the blade package.

Viewed in another aspect, the present invention provides, incombination, a surgical blade package and a surgical blade containedtherein, the blade having a slot formed therein for receiving aforwardly projecting cleat on a scalpel as the scalpel is inserted intothe package. Following use of the blade in an operating room or othermedical or surgical environment, the blade may be stripped of thescalpel by reinserting the cleat into the package, thereby eliminatingor at least substantially minimizing the risk of injury by an accidentalor inadvertent contact with the blade. Means are provided for supportingthe blade within the package and for preventing an inadvertent dullingof the blade during manufacture, shipment or storage thereof, andreleasable means are provided on the package for holding and retainingthe blade prior to insertion of the scalpel into the package. Thescalpel is inserted beneath the rear portion of the blade and betweenthe blade and a bottom wall of the package, and the scalpel is movedforwardly and upwardly (not downwardly as in our previous patents)relative to the package to mount the blade on the scalpel as the bladeis completely removed from the package. After a surgical procedure, theblade is re-inserted within the package and the relative movement of thescalpel and package is reversed to strip the blade off the scalpel;thereafter, the nurse or technician uses the releasable means to againretain the blade prior to disposal of the package with the blade into asharps container or other disposable means.

Preferably, the means for supporting the blade within the packagecomprises a transverse ledge formed on the package. In one embodiment,this ledge is formed between parallel side walls of the package andintermediately of the length of the package.

The releasable means for holding down and retaining the blade comprisesa tab integrally connected to the package by a living hinge.

Viewed in yet another aspect, the present invention provides a method ofmore easily and conveniently mounting a surgical blade on theforwardly-projecting cleat of a scalpel, and for subsequently removingthe blade from the scalpel following use of the blade during a surgicalprocedure in an operating room or other medical environment, therebyeliminating or at least substantially minimizing the risk of injury dueto an accidental or inadvertent contact with the blade. This improvedmethod includes the steps of provides a package having a blade therein,the blade being disposed between respective side portions of the packageand further being recessed below the open top the package. A tab isformed on the package and partially covers the open top of the packageabove the blade. The package is held with one hand while holding thescalpel with the other hand. The cleat on the scalpel is insertedunderneath the rear portion of the blade and between the blade and thepackage. The scalpel is moved forwardly and upwardly with respect to thepackage such that the cleat on the scalpel is received within the sloton the blade, and such that diametrically-opposite slits on the cleatengage the respective adjacent sides of the slot in the blade. Theforward movement of the scalpel is continued, such that the tab on thepackage is pushed away as the package is separated from the blade andthe blade is mounted on the scalpel.

Following use of the scalpel with the blade mounted thereon during asurgical procedure, the improved method includes the steps of picking upthe package; maintaining the flap down on the package; reinserting theblade into the package to completely strip the blade away from thepackage; and thereafter disposing of the package with the blade thereinin a suitable container.

In accordance with the teachings of the present invention, the improvedsurgical blade package may be used with a standard (unguarded) scalpelhandle or with a guarded surgical scalpel as disclosed and claimed inour following United States Letters patents:

U.S. Pat. No. 5,250,063

U.S. Pat. No. 5,275,606

U.S. Pat. No. 5,411,512

U.S. Pat. No. 5,496,340

U.S. Pat. No. 5,569,291

U.S. Pat. No. 5,662,669

These and other objects of the present invention will become apparentfrom a reading of the following specification, taken in conjunction withthe enclosed drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the improved surgical blade package ofthe present invention.

FIG. 2 is a top plan view thereof, the broken lines indicating theblade.

FIG. 3 is a longitudinal section view, taken along the lines 3—3 of FIG.2, and with certain parts shown in elevation and section, respectively.

FIG. 4 is a forward end view (the closed end) of the blade package ofFIG. 1.

FIG. 5 is the rear opposite end view (the open end) of the package.

FIG. 6 is a cross-sectional view, taken along the lines 6—6 of FIG. 2,and showing the blade between the pivoted tab (or flap) and thetransverse ledge for supporting the blade thereon.

FIGS. 7A–7D and 8A–8D are respective sequence views, illustrating themounting of the blade on the scalpel.

In FIGS. 7A and 8A, the scalpel handle is held in one hand and the bladepackage in the other hand.

In FIGS. 7B and 8B, the forwardly-projecting cleat on the scalpel isinserted through the open end of the package, beneath the blade, andbetween the blade and the bottom wall of the package.

In FIGS. 7C and 8C, the cleat on the scalpel is fully inserted into themounting slot on the blade, as the cleat is moved forwardly and upwardlyrelative to the package.

In FIGS. 7D and 8D, the forward, upward movement of the scalpel iscontinued (it's all one continuous movement to “snap” the blade on thescalpel) and, as shown, the package is completely disengaged from thescalpel.

FIG. 9 is a flow chart, showing the sequential steps in mounting theblade on the scalpel and disengaging the blade package (which is savedfor subsequent disposal of the used blade).

FIGS. 10–14 illustrate the sequential steps of the stripping the usedblade off the scalpel, using the original blade package (andsubstantially reversing the steps in snapping or inserting the blade onthe scalpel) for subsequent disposal of the package (with the used bladetherein) in a suitable “sharps” container (FIG. 14).

FIGS. 15–18 illustrate a further embodiment, wherein anupwardly-projecting integrally-molded stud cooperates with a hole in theblade for precluding lateral movement of the blade in the package duringmanufacture, shipment and/or storage, thereby precluding inadvertentdulling of the blade.

FIG. 15 is a top plan view of this further embodiment of the blade andits package.

FIG. 16 is a top plan view of the blade of FIG. 15.

FIG. 17 is a longitudinal section, taken along the lines 17—17 of FIG.15 and showing the pivoted tab lifted away from the blade.

FIG. 18, drawing to an enlarged scale, illustrates the cooperation ofthe upstanding pin or stud and the hole (or other opening) in the blade.

FIGS. 19–22 show a still further embodiment, wherein cooperating nibsare formed between the pivoted tab and the side walls of the bladepackage for a stronger cooperation therebetween.

FIG. 19 is a partial top plan view thereof, drawn to an enlarged scale.

FIG. 20 is a full top plan view thereof.

FIG. 21 is a cross-sectional view thereof, taken along the lines 21—21of FIG. 20, and drawn to an enlarged scale.

FIG. 22 is a longitudinal section view thereof, taken along the lines22—22 of FIG. 20, and showing alternate positions of the pivoted tab inbroken lines.

FIG. 23 is a cross-sectional view, drawn to an enlarged scale, showingthe cleat on the scalpel received in the mounting slot in the blade, theside edges of the blade (adjacent to the mounting slot in the blade)being recessed within the diametrically-opposite slits in the cleat onthe scalpel handle.

FIG. 24 is a perspective view of the blade package of the presentinvention (with the surgical blade therein) recessed within a sterilepouch (or other sterile container).

GENERAL DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference to FIGS. 1–6, the improved blade package 10 houses asurgical blade 11. The package 10 has an open top 12, side walls 13 and14, a bottom wall 15, a closed forward end 16 and an open rear end 17. Apivotable tab (or flap) 18 partially covers the open top 12 and isjoined to the package 10 by an integrally-molded “living” hinge 19. Thetab 18 has a raised thumb rest 20. The blade 11 is supported upon atransverse ledge 21 joining the respective side walls 13 and 14intermediately the length of the blade package 10. The side walls 13 and14 have indented or scalloped recesses 22 and 23, respectively, adjacentto the open rear end 17 of the package 10 and, preferably, theserecesses 22 and 23 are suitable grooved (or knurled or roughened) asshown for holding the blade package 10 between the thumb and forefinger.The open rear end 17 of the package 10 (see FIG. 1) has guides 24 and25, respectively, for slidably guiding the scalpel into the bladepackage 10 (as hereinafter described).

With reference to FIGS. 7A–7D, 8A–8D and 9, the forwardly-projectingcleat 26 on the conventional scalpel handle 27 is inserted beneath therear end portion 28 of the blade 11 and between the blade 11 and thebottom wall 15 of the package 10 (FIGS. 7B and 8B) and the cleat 26 iscontinued upwardly and forwardly (FIGS. 7C and 8C) until the blade 11snaps on to the cleat 26 on the scalpel 27 and the blade package 10 isdisengaged from the scalpel 27 (FIGS. 7D and 8D) in one continuousupward and forward movement.

With reference again to FIG. 9, the blade package 10 may be pulled awayfrom the scalpel 27 (all in one motion) or, if desired, the operator'sthumb and forefinger may be shifted into the scalloped concave recesses22 and 23, respectively, to assure a better manual grip and obtain moreleverage.

Once the blade 11 has been used in a surgical procedure, the reversesteps may be employed to re-position the (used) blade 11 in the originalpackage 10 for disposal purposes.

This reverse procedure is shown in FIGS. 10–14, respectively. Again, thescalpel 27 (with the used blade 11 thereon) is held in one hand (FIG.10) and the blade 11 is inserted into the package 10 (FIG. 11) andcontinued therein (FIG. 12) to strip the blade 11 off the scalpel 27,whereupon the blade 11 is wholly within the package 10 and completelyremoved from the scalpel 27 (FIG. 13) so that the package 10 (with theused blade 11 therein) may be tossed into a conventional “sharps”container 29.

With reference to FIGS. 15–18, a modification is illustrated wherein thetransverse ledge 21 on the blade package 10 has an upstanding pin orstud 30 (or other projection) received in a hole 31 (or other opening)formed in the blade 11. The cooperation therebetween provides additionalassurance that the blade 11 will not shift laterally during manufacture,shipment and/or storage of the blade package 10, thereby assuring thatthe tip 32 and cutting edge 33 of the blade 11 will not become dulled ornicked.

With reference to FIGS. 19–22, a second modification is illustratedwherein the pivotable tab 18 has a pair of oppositely-disposedprojections or nibs 34 (FIG. 21) received in cooperating recesses 35 inthe sidewalls 13 and 14, respectively, of the blade package 10, therebymore securely retaining the pivotable tab 18 against accidental orinadvertent dislodgement from the open top 12 of the blade package 10.The retaining force of these nibs 34, however, will not interfere withthe upwardly and forwardly movement of the scalpel 27 to mount the blade11 on to the cleat 26 of the scalpel 27 and, using the inherentmechanical advance, pivot the tab 18 away from the open top 12 of theblade package 10 (FIG. 22).

With reference to FIG. 23, and as is conventional, the side edges 36 and37, respectively, of the blade 11 (adjacent to the mounting slot 38 arereceived in the slits 39 and 40, respectively, of the cleat 26 on thescalpel 27.

With reference to FIG. 24, the blade package 10 may be received in asuitable pouch 41 (which is sterilized). In lieu of the pouch 41, ablister pack, foil or other suitable container (not shown) may beemployed for the blade package 10.

As will be appreciated by those skilled in the art, the blade package 10of the present invention is a decided improvement over the prior art(including our own patents) and constitutes an important and valuablecontribution in the art. Not only is the operation different andsuperior (an upward movement rather than a downward movement) but, evenmore significantly, the original blade package 10 becomes the disposablepackage or container for the used blade 11.

Obviously, many modifications may be made without departing from thebasic spirit of the present invention. Accordingly, it will beappreciated by those skilled in the art that within the scope of theappended claims, the invention may be practiced other than has beenspecifically described therein.

1. The method of easily and conveniently mounting a surgical blade onthe forwardly-projecting cleat of a scalpel, and for subsequentlyremoving the blade from the scalpel following use of the blade during asurgical procedure in an operating room or other medical environment,thereby eliminating or at least substantially minimizing the risk ofinjury due to an accidental or inadvertent contact with the blade,comprising the steps of providing a package having a blade therein, theblade being disposed between respective side portions of the package andfurther being recessed below the open top of the package, a tab formedon the package and partially covering the open top of the package abovethe blade, holding the package with one hand while holding the scalpelwith the other hand, inserting the cleat on the scalpel underneath therear portion of the blade and between the blade and the package, movingthe scalpel forwardly and upwardly with respect to the package such thatthe cleat on the scalpel is received within the slot on the blade, andsuch that diametrically-opposite slits on the cleat engage therespective adjacent sides of the slot in the blade, and continuing theforward movement of the scalpel such that the tab on the package ispushed away as the package is separated from the blade and the blade ismounted on the scalpel.
 2. The method of claim 1, wherein the packagehas side walls provided with cooperative scalloped recesses, and furtherincluding the step of holding the package by the thumb and forefinger inthe respective scalloped recesses.
 3. The method of claim 1, wherein theblade package is molded plastic, wherein the tab is integrally moldedwith the package and is connected thereto by a living hinge, and furtherincluding the step of manually holding down the tab temporarily as thescalpel is inserted into the blade package.
 4. The method of mounting ablade onto a surgical scalpel without physically touching the blade,thereby avoiding an accidental or inadvertent contact with the bladeboth before and after a surgical procedure, comprising the steps ofproviding a blade package having a blade positioned therein, the packagehaving a bottom and further having a pivotable flap, and the bladehaving a tip and a cutting edge and further having a rear portion spacedfrom the bottom of the package, inserting the scalpel below the rearportion of the blade and between the blade and the bottom of thepackage, and moving the scalpel into the package forwardly and upwardlythereof, such that the blade is mounted on the scalpel as the pivotableflap is pushed out of the way, and the package is completely separatedfrom the scalpel; and following use of the scalpel with the blademounted thereon during a surgical procedure, picking up the package,maintaining the flap down on the package, and re-inserting the bladeinto the package to completely strip the blade away from the package,and thereafter disposing of the package with the blade therein in asuitable container.
 5. The method of safely and conveniently mounting asurgical blade onto a scalpel and subsequently stripping the blade afteruse in a surgical procedure for safe disposal of the used blade,comprising the steps of providing a scalpel having aforwardly-projecting cleat thereon, providing a blade package having abottom portion and further having a blade mounted in the blade package,the blade package having an accessible rear portion and the blade havinga rear portion spaced vertically from the bottom portion of the bladepackage, inserting the cleat on the scalpel through the accessible rearportion of the blade package and between the rear portion of the bladeand the bottom portion of the blade package, and moving the scalpel andthe blade package towards each other as the scalpel is moved upwardlyand forwardly relative to the blade package, such that the cleat on thescalpel engages the blade as the blade package is pulled away from theblade, thereby mounting the blade on the scalpel; and after use of theblade in a surgical procedure, re-inserting the cleat of the scalpelwith the used blade mounted thereon through the accessible rear portionof the blade package and directly above the bottom wall thereof, andmoving the scalpel and blade package away from each other, such that theblade is stripped from the scalpel and simultaneously remounted withinthe blade package; and subsequently safely disposing of the bladepackage with the used blade therein.
 6. The method of claim 5, whereinthe scalpel comprises a conventional scalpel handle.
 7. The method ofclaim 5, wherein the scalpel comprises a guarded surgical scalpel. 8.The method of claim 5, wherein the cleat has respective side portionsprovided with longitudinal slits, and wherein the blade has a mountingslot formed therein, the mounting slot having side edges received withinthe respective slits on the cleat.